A framework of an ultra-precision roller machining equipment for the fabrication of patterned microstructured optics

Patterned microstructured surfaces are widely adopted in advanced optics applications such as LED backlight guide, which can be fabricated by precision roller embossing. Ultra-precision rollers with microstructured patterns are key components for the precision roller embossing process. However, ultra-precision roller is not only difficult to be fabricated due to the heavy load and high precision requirements, but is also expensive in terms of its manufacturing cost. This paper presents a framework for research and development of an ultra-precision roller machining equipment for the fabrication of ultra-precision rollers for the precision embossing of microstructured optics applications. The framework includes the machine design concepts and key technologies, such as the machine mechanical configuration, development breakdown, and some key technologies including roller cutting mechanism, tool path planning and generation, pattern mapping from plane to roller, cutting tool position setup and error analysis, etc. Compared with the existing equipments for ultra-precision roller machining, the designed machine equipment aims to be high precision which can be produced in a low cost. This allows the equipment can be potentially used in mass production to support optical-electro-mechanical industries in Mainland China.